Wire cutting electrical connector having test probe access

ABSTRACT

A wire connector (2) comprising a cover (8) and a body (4) for carrying a wires (84) therebetween. A U-shaped connection element (6) includes a first leg (48) for engaging a wire (84) positioned within the body (4) and a second leg (52) sharpened to sever the end of the wire (84), wherein the body (4) and the cover (8) include co-operating latch structure (30,32), to define an open position, where the wire (84) may be inserted into the connector (2) and a crimped closed position where the body (4) and the cover (8) are fully telescoped together whereby the excess end of the wire (84) is severed and the connector element (6) engages at the wire at the end connection slots (50). In the closed position, the connection element (6) is accessible in a manner that enables a test probe (78) to engage the connection element (6) through cover means (72) which is provided in a normally biased closed position and that is retained in the closed position without the need for latch means.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to an electrical connector for electricallyengaging at least one electrical conductor and severing the end thereof.

2. Summary of the Prior Art

There are numerous electrical connectors that perform a severing and aconductor engaging operation simultaneously during termination. Someexamples are: U.S. Pat. No. 3,202,957; U.S. Pat. No. 4,326,767; U.S.Pat. No. 4,496,206; and U.S. Pat. No. 4,444,447.

In particular, U.S. Pat. No. 3,202,957 discloses a U-shaped connectionelement where the first leg of the U includes slot for engaging a wirein an insulation displacement (IDC) manner. The other leg of the U issharpened such that it would cut the wire simultaneously with thetermination by the first leg, whereby excess wire is removed and thewire is electrically engaged in response to a single movement of theconnection element.

U.S. Pat. No. 4,326,767 discloses a wire connector having a body thatcarries a U-shaped connector element similar to that described abovewith reference to U.S. Pat. No. 3,202,957 and insulating cover thattelescopes with the body in order to carry a wire into the connectionslots of the connector element and against the sharpened second leg ofthe connector element to sever the end of the wire simultaneously withtermination, wherein the body and the cover include co-operating latchstructure to define an open position where wires may be inserted intothe connector and a crimped closed position where the body and the coverare fully telescoped together whereby the excess end of the wire issevered and the connector element engages the wire at the connectionslots thereof. It is further disclosed to include co-operating covermembers to seal the end of the wire connector after the wire ends havebeen severed and displaced, thereby preventing contaminants fromentering or sealing means, such as grease, from exiting. Finally, aninclined wall is provided in a supporting relationship with thesharpened blade of the connector element that ejects the wire and as thecover and body are telescoped together into the closed position.

While the afore mentioned connectors perform admirably it is desired toimprove on a number of short comings. A first problem is with theco-operating cover members disclosed in U.S. Pat. No. 4,326,767. Thesecover members involve a door formed as part of the cover and having itsnormal bias as the open position. In order to close the door and therebyseal the connector unit a user must displace the door such thatco-operating latch structure upon the door and another component of thewire connector. This leads to the possibility that the installer mayforget to close the cover or that if the latch members become dislodgedthe cover will open. Another disadvantage of the afore mentionedconnector structure is that it is difficult to test the continuity ofthe electrical interconnection. The typical method of doing so would beafter the cover and body are fully telescoped together, such that theconnector element is engaged upon the wire and the wire ends have beensevered, using a probe to touch the second leg of the connector elementwhere it is now exposed by the vacated wire end. A problem with thisprocedure is that in order to assure a clean severance of the wire end,a sharpened second blade must extend completely across the channel suchthat a test probe may only be brought against the sharpened second legand must be held in physical contact therewith. This procedure isdifficult for the installer as both hands must be involved in holdingthe connector and in holding the testing device. A further disadvantageoccurs when it is necessary to test the continuity of theinterconnection of the connector described above once the cover door hasbeen latched in place. In this instance it is necessary for theinstaller to first pry the co-operating latch members apart such thatthe door may be opened to provide access to the sharpened second leg ofthe connector element. This could lead to damage of the latch memberswhereby the connector door could not be completely closed and latched inposition.

Therefore, it would be advantageous to provide a connector of the typedescribed above with a cover member that is normally biased to theclosed position, thereby assuring the connector will remain sealed.Furthermore, it would be advantageous to maintain the closed positiondue to the elasticity of the hinge, thereby eliminating the need forco-operating latch members such that the cover means may be easilyopened for later testing or access.

It would be advantageous to provide an electrical connector as generallydescribed above with an access port that provides access to the U-shapedconnector element in a manner that enables a test probe to engage and bepositively retained with the connector element therein. It would beespecially advantageous to include this access beneath the cover meansthat are used to cover the channels after removal of the severed wireends.

SUMMARY OF THE INVENTION

The aforegoing objects are met by providing a connector according toclaim 1. Additional advantageous developments are realized throughconnectors according to the subsequent dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of an electrical connectoraccording to the present invention and including a representation of atest probe;

FIG. 2 is an upper perspective view of the body of the electricalconnector of FIG. 1;

FIG. 3 is a partially exploded rear perspective view of the electricalconnector of FIG. 1 showing the U-shaped connector element within thebody;

FIG. 4 is a top view of the electrical connector of FIG. 1 fullyterminated upon a pair of wires;

FIG. 5 is a cross-sectional view of the electrical connector of FIG. 5taking along line 5--5; and

FIG. 6 is the same cross-sectional view of FIG. 5 with therepresentative test probe inserted within the access port.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference first to FIGS. 1-3, an electrical connector according tothe present invention is shown generally at 2. The electrical connector2 includes a main body 4, a U-shaped connecting element 6 and a covermember 8. The main body 4 includes a base 10. Extending from the base 10is a nose portion 12. Located upon the base 10, is wire positioningstructure 14. The wire positioning structure 14 includes a forwardabutment 16 and a rearward abutment 18. The rearward abutment 18comprises a vertical surface 20 extending upward from the base 10 and aninclined sealing surface 22. A pair of wire receiving channels 24 extendthrough the abutment 16,18 of the wire positioning structure 14 andacross a gap 26 between first abutment 16 and the nose 12 where thechannels 24 then pass through the nose portion 12. Each of the channels24 are open on one side thereof by slots 28 such that the channels 24have a C-shaped cross-section, which enables the necessary resilience ofthe structure. Spanning the abutment walls 16,18 are first and secondpositioning rails 30,32 respectively. The pairs of first positioning 30are separated from the pair of second positioning rails 32 by thecorresponding slots 28. Each of the positioning rails 30,32 include atapered camming surface 34 followed by a scalloped seat 36. The taperedlead-in surfaces 34 and the scalloped seats 36 co-operate with a rib(not shown) within the cover member 8 to define a preassembled positionwhere wires may be inserted into the connector 2 when the connectorcover 8 is telescoped over the body 4 the rib passes over the cammingsurfaces 34 of the first positioning rail 30 to be received within thescalloped seats 36 thereof. Once disposed within the scalloped seats 36,sufficient force must be exerted to further telescope the cover 8relative to the body 4 such that wire termination occurs as describedbelow. When adequate force has been exerted the ribs come out of thescallop seat 36 of the first rails 30 and pass thereover and into theslots 28 and then come in contact with the camming surface 34 of thesecond rails 32. Further exertion of force results in the cammingsurfaces 34 causing the ribs to bias outward and enter scallop seats 36.The second rails 32 to define the fully closed position wherein thewires will be electrically engaged by the contact member 6. Locatedbetween the abutment walls 16,18 along each of the channels 24 oppositethe slots 28 are separation partitions 38. Each of the separationpartitions 38 are separated from the abutment walls 16,18 by connectorelement receiving gaps 40,42 (FIG. 2). Located between the separationpartitions 38 is a probe clearance region 44. An access port 46 extendsthrough the second abutment wall 18 and is aligned with the probereceiving clearance region 44 in order to enable the test probe 78 toengage the connection element 6.

The connection element 6 (FIG. 1) is a U-shaped conductive elementhaving a first leg 48 with at least one connection slot 50 configured toelectrically engage a conductive element, such as an insulated wire, asa result of being displaced thereover. One particular example would bean insulation displacement contact configuration. Opposite the first leg48 is a second leg 52 having a bevelled cutting edge 54 at its free end.A gap 56 is formed roughly at the centre of the free end of the secondleg 52. The legs 48,52 are interconnected by a base 58. The base 58includes a pair of holes 60 enabling the connection element 6 to beaffixed to the cover member 8 by such means as heat staking a pylon (notshown) that would extend therethrough as is common in industrialpractice.

The cover member 8 that would carry the connection element 6 and betelescopically received upon the body 4 is a generally hollow memberhaving opposing sides 62 interconnected by a cover member 64 and aforward plate 66. Opposite where the opposing sides 62 meet with theforward plate 66 are a pair of end legs 68. The end legs 68 areseparated by a gap 70 formed therebetween. A flap 72 is joined to thecover 64 along a seam 74, whereby an elastic hinge is formed having itsnatural or relaxed position such that the inclination of the flap 72corresponds approximately to the inclination of the inclined wall 22 ofthe second abutment 18 for purposes of sealing the second abutment aswill be described below. It may also be desirable to have the flap at aninclination greater than that of the inclined surface so that aresilient force would be exerted therebetween to assure the flap remainsagainst the inclined surface. At the extreme end of the flap 72 is arail 76 for manipulating the flap 72. The flap 72 is configured to fitbetween the legs 68 without interference therebetween. The flap 72 couldalso be deformable and joined to the cover member 8 along end legs 68thereof.

A representative test probe is shown generally at 78. The test probe 78includes a body 80 from which an advantageous hook-like member 82extends. The hook-like member 82 may be spring loaded as is common inelectrical measuring instruments. The access port 46 is sized to receivethe hook-like member 82.

The cover 8 is telescopically received over the wire positioning member14 such that the side walls 62 encompass the positioning rails 30,32 sothat the ribs positioned along the inner surfaces of the side walls 62may be engaged by the rails 30,32. With wires received within thechannels 24 and extending beyond the second abutment 18, as the cover 8is brought down the rail 76, the flap 72 will make contact with thewires. The interference between the rail 76 of the inclined flap 72 andthe wires results in the flap being deformed outward between the legs 68such that as the cover 8 is being brought down in a telescopic mannerupon the body 4 the flap displaces further outward. When the cover 8 ismoved from the reassembled position to the fully latched position theresilient hinge formed along seam 74 is elastically displaced as thewires are engaged in the slots 50 of the connection element 6. Duringthis time the second sharpened leg 52 of the connection element 6 seversthe ends of the wires which are supported within the portion of thechannels 24 within the abutment wall 18. A combination of the supportprovided by the abutment wall 18 and the interference with the resilientflap 72 result in the wire ends being retained within the connectorhousing 2. Once the ribs of the cover 8 are received within the secondpositioning rails 32 the installer may remove the wire ends. Theresilient flap 72 by way of the elasticity of the hinge 74 and thememory aspect of the material used results in the hinge with the cover 8drawing the flap 72 against the inclined surface 22, thereby sealing theopen channels 24.

With reference now to FIG. 4, the electrical connector 2 is shown fullyterminated upon a pair of wires 84. The nose portion 12 encompasses thewires and provides strain relief thereto. The cover 8 has beentelescopically disposed upon the body 4 and the flap 72 is shown in itsnatural position against the inclined surface of the second abutmentwall 18. As can further be observed in FIG. 5, the rail 76 extendsoutward from the vertical portion 20 of the second abutment 18. Where itis desired to test the continuity of the electrical interconnectionformed at the first leg 48, by lifting the flap 72 at rail 76 the testprobe 78 may be inserted into the connector 2 by way of axis port 46,best seen in FIG. 6.

With further reference to FIG. 6, the hook-like member 82 of the testprobe 78 passes into the port 46 and, by way of the notch 56 behind theconnection element 6 so that it may become engaged therewith todetermine the electrical interconnection. As can be observed, the flap72 may wedge against the body 80 of the test probe 78 to interferetherewith to assist in retaining the test probe in position. As istypical for test probes, the contacting portion 82 would be springloaded and this interference would result in an advantageous, althoughnot necessary positive engagement therebetween. It may also be possiblefor the test probe 78 to be engaged with other portions of the connector2 structure.

We claim:
 1. A wire connector comprising a cover and a body having apair of channels for receiving respective wires therein, a connectorelement is positioned therebetween and includes a first leg for engagingthe wires when positioned within the body in order to common said wiresand a second leg sharped to sever an excess end of the wires, whereinthe body and the cover have an open position where the wires may beinserted into the connector and a closed position where the body and thecover are fully telescoped together and latched together by cooperatinglatch structure where the excess end of the wires are severed and theconnector element engages the wires, and sealing means are included forsealing an opening from which the excess wire ends are removed, theconnector the body further includes an access port located behind thesealing means and extending into the body along the channels where theaccess port is in communication with the connector element such that theconnector element is contactable by a test probe inserted into theaccess port and the sealing means is normally biased to the closedposition.
 2. The wire connector of claim 1, further characterized inthat said sealing means is a flap that is joined to the cover through anelastic hinge such that the flap deforms upon telescoping of the bodyand cover as a result of interference with the excess end of the wireand the flap resiles to the sealed position upon removal of theinterference.
 3. The wire connector of claim 2, wherein the, thechannels are separated by the access port.
 4. The wire connector ofclaim 3, wherein the connector element includes a gap formed in thesecond leg thereof where said gap is aligned with the access port. 5.The wire connector of claim 1, wherein the cover has a latched firstposition upon the body where the wires can be received therein.
 6. Thewire connector of claim 1, wherein the connector element is U-shaped andaffixed to the cover.
 7. The wire connector of claim 6, wherein theconnector element is of one piece construction.